Motor control system



Narman km 8 Pw w i me Q Mm m @m B.'O. AUSTIN ET AL MOTOR CONTROL SYSTEM Original Filed Jan. 2, 1935 Aug. 23, 1938.

Patented Aug. 23, 1938 UNITED STATES PATENT OFFICE MOTOR CONTROL SYSTEM Bascum 0. Austin, For

est Hills, and Norman H.

Willby, Irwin, Pa., assignors to Westinghouse Electric & Manufacturing Company, East Pittsburgh, Pa., a corporation of Pennsylvania 6 Claims.

This application is a division of our copending application, Serial No. 68, filed January 2, 1935, now Patent No. 2,078,216, issued April 27, 1937.

Our invention relates generally, to motor control systems, and, more particularly, to systems for controlling the operation of the propelling motors of electric vehicles, such as street cars and trolley buses.

An object of our invention, generally stated, is to provide a motor control system which shall be simple and efiicient in operation and which may be economically manufactured and installed.

A more specific object of our invention is to provide an automatic control system for controlling the current in the motors of an electrically propelled vehicle during dynamic braking of the vehicle.

A still further object of our invention is to prevent the progression of an automatic control systern during dynamic braking of the motors until the motor voltage has attained a predetermined value.

Other objects of our invention will be explained fully hereinafter or will be apparent to those skilled in the art.

In accordance with one embodiment of our invention, the progression of an automatic control system is governed by a plurality of limit relays, one of which may be provided for each step of the control system. The limit relays are so connected in the system that they are successively energized as the accelerating switches are closed and each switch in the progression cannot close until the motor current is of such a value that its respective limit relay operates to energize the switch. During dynamic braking, the same resistors and switches are utilized to control the motor current as during acceleration, but the automatic progression is prevented from starting until the motor voltage has built up to a predetermined value. Variable rates of acceleration and braking are obtained by providing actuating coils on the limit relays having a plurality of taps which are governed by the master controller.

For .a fuller understanding of the nature and objects of our invention, reference may be had to the following detailed description, taken in conjunction with the accompanying drawing, in which:

Figure 1 is a diagrammatic view of a motor control system embodying our invention; and

Fig. 2 is .a chart showing the sequence of op eration of certain of the switches illustrated in Fig. 1.

Referring now to the drawing, the system shown comprises a pair of electric motors l0 and II, which may be of any type suitable for propelling a trolley bus or other electrically-propelled vehicle. The motors shown are of the series type, the motor 10 having an armature winding I2 and a series field winding l3, and the motor H having an armature winding l4 and a series field winding I5. Electrically operated switches l6 and H are provided for connecting the motors in and H to current-collecting devices I8 and I9, which engage overhead power conductors 2| and 22, respectively. A plurality of resistors 23, 24 and 25 are provided for controlli'ng the motor current during the acceleration of the motors, and electrically operated switches 26, 21 and 28 are provided for shunting the resistors 23, 24 and 25, respectively. In addition to the foregoing resistors, a resistor 29 is utilized during dynamic braking of the motors to control the motor current, and electrically operated switches 3| and 32 are provided for establishing the dynamic braking connections for the motors. A master controller 33, which may be of the drum type, is provided for controlling the motors while they are propelling the vehicle and a similar controller 34 is utilized during dynamic braking. The two controllers are so electrically interlocked that it is necessary for the accelerating controller 33 to be in the off position before the controller 34 can be effective in establishing the braking connections.

In order that the acceleration, and also the dynamic braking of the vehicle, may be automatically controlled, as Well as manually, by means of the controllers 33 and 34, current limit relays 35 and 36 are provided for automatically controlling the operation of the resistor shunting or accelerating switches 21 and 28 as will be more fully described hereinafter.

With a view to preventing the skipping of notches or steps and to ensuring that the motor current has dropped to the proper value before additional resistance is shunted from the motor circuit, a limit relay is provided for each step in the automatic progression, and each limit relay controls only one of the accelerating switches, instead of one limit relay controlling all of the switches, as in previously known systems. The limit relays are so connected in the motor circuit that they are successively energized by the motor current as each step of resistance is shunted from the motor circuit by the accelerating switches. The next switch in the progression cannot operate until permitted to do so by the limit relay that was energized by the closing of the preceding switch.

As shown, each current limit relay is provided with two coils which are disposed on the relay in opposed relation. In this instance a series coil pulls down on the relay armature and a shunt coil pulls up. When neither coil is energized, the relay is actuated by gravity to its lowermost position, in which position the contact members of the relay are open and they can be closed only by the shunt coil raising the relay armature. Since the series coil is energized by the motor current in the foregoing manner and the shunt coil is energized by the trolley potential, it will be seen that the relay cannot close until the motor current falls to a value which will permit the shunt coil to overcome the series coil. Thus, the next switch in the progression cannot operate until the motor current has dropped to a predetermined value.

In order that variable rates of acceleration, and also dynamic braking, may be obtained, the shunt coils on the limit relays may be provided with one or more taps, the connections to which are controlled by the master controller. In this manner the maximum rate of acceleration may be obtained by energizing the entire shunt coil windings, or a lower rate may be obtained by energizing only a portion of the windings through their respective taps.

In order to insure that the voltage of the machines IE! and II will build up quickly when dynamic braking connections are established, the field winding l5 of the motor II is connected to the power source through a resistor 31 during the first part of the braking cycle. After the voltage of the machines has once built up, it is no longer necessary to separately excite the field winding of the one machine.

With a view to preventing the resistor shunting switches from being automatically operated before the voltage of the machines I!) and II has built up, when the dynamic braking connections are established, a relay 38 is connected across the machines It] and H to be responsive to the voltage of the machines. The contact members of the relay 38 are so connected in the control system that the operation of the resistor shunting switches cannot take place until the voltage of the machines H1 and ll has been built up to a predetermined value. However, the relay 38 is effective only during dynamic braking and not during acceleration of the motors.

With a view to simplifying the drawing and the description of the control system, only a few steps of resistance have been shown in the motor circuit. It will be understood that additional resistors, accelerating switches and limit relays may be readily provided, if desired.

In order that the functioning of the foregoing apparatus may be more clearly understood, the operation of the system will now be described. Assuming that it is desired to accelerate the vehicle under manual control of the operator, the master controller 33 may be actuated to position I, thereby energizing the actuating coils of the line switches l6 and I1, which causes the motors ii) and I l to be connected to the current collectors I 8 and I9. The energizing circuit for the coil of the line switch I! may be traced from the positive power conductor 2| through the current colloctor l8, conductor 4|, contact fingers 42 and 43, bridged by a contact segment 44 on the controller 33, conductors 45 and 4B, the actuating coil 41 on the line switch ll, conductors 48 and 49,

and the current collector l 9 to the negative power conductor 22. The circuit through the actuating coil of the line switch it extends from the previously energized conductor 45 through the actuating coil 5|, conductor 52, an interlock 53 on the switch 3!, conductor 54, an interlock 55 on the switch II and conductor 48 to the negative conductor 49.

The motors ill and i l are now connected to the power source in parallel-circuit relation. The circuit through the motor Ill may be traced from the positive conductor 21 through the current collector l8, conductors 4i and 57, contact members 58 on the switch l6, conductor 59, the resistors 23, 24 and 25, conductor 5|, contact members 62 on the switch l6, conductor 53, the field winding l3 and armature winding 12 of the motor I0, conductors E4 and 65, contact members 66 on the switch I1, conductor 6'! and the current collector I9 to the negative conductor 22. The circuit through the motor I! extends from the previously energized conductor 63 through conductor 68, the armature winding l4 and the field winding 55 of the motor II to the conductor 65,

and thence through the circuit previously traced to the negative conductor 22.

Since the motors in and I! are connected in series with the resistors 23, 24 and 25, they will rotate at a low speed. The motors may be accelerated in a manner well known in the art by moving the controller 33 to position 2, thereby closing the accelerating switch 26 to shunt the resistor 23 from the motor circuit. The energizing circuit for the actuating coil of the switch 26 may be traced from a contact finger 'H, which engages the segment 44, conductor 72, the actuating coil 73 on the switch 26, and conductor 14 to the negative conductor 49. When the switch 25 is actuated to its uppermost position, the contact members '15 are closed to shunt the resistor 23 from the motor circuit.

It will be noted that the series coil 76 of the limit relay 35 is connected in the motor circuit when the resistor shunting switch 26 is closed. Therefore, the series coil 16 is energized by the motor current. The operation of the switch 26 also completes the energizing circuit for a portion of the winding of the shunt coil of the limit relay 35. The energizing circuit for the shunt coil may be traced from a contact finger 11, which engages the segment 44 on the controller 33, conductors 18, 19 and BI, the lower portion 82 of the winding of the shunt coil on the relay 35, conductors 83 and 84, an interlock 85 on the switch 25, and conductor 86 to the negative conductor 49.

As explained hereinbefore, the limit relay 35 will be raised to its uppermost position when the motor current is reduced to a value which will permit the shunt winding 82 on the limit relay to overcome the force exerted by the series winding 75, thereby permitting the next step of acceleration to be taken.

Assuming that the limit relay 35 is raised to its uppermost position, the actuating coil of the switch 27 may be energized to close this switch by moving the controller 33 to position 3. The energizing circuit for the actuating coil of the switch 21 may be traced from a contact finger 8'! through conductors 88 and 99, the coil 9| on the switch 2T, conductor 92, contact members 93 on the limit relay 35, conductor 84, the interlock 85 on the switch 26, and conductor 86 to the negative conductor 49. In this manner, the contact members 94 of the switch 2'! are closed to shunt the resistor 24 from the motor circuit, thereby completing the second step in the acceleration of the motors I0 and II.

The limit relay 36 functions in a manner similar to the relay 35 to prevent the next step of acceleration from being taken until the motor current is reduced to a predetermined value. The series coil 95 is energized by the motor current when the contact members 94 of the switch 21 are closed and a portion of the shunt winding is also energized at that time. The circuit through the shunt winding may be traced from the previously energized conductor I9, through the lower portion 96 of the shunt winding on the relay 35, conductors 91 and 98, an interlock 99 on the switch 21 and conductor IN to the negative conductor 49.

Accordingly when the motor current is reduced to the value which will permit the shunt coil of the relay 36 to overcome the series coil 95 and raise the relay to its uppermost position, the switch 28 may be closed by actuating the controller 33 to position 4. The energizing circuit for the actuating coil of the switch 28 may be traced from a contact finger I02, which engages the contact segment 44, conductors I03 and I04, the actuating coil I 05, conductor I06, contact members I01, on the limit relay 36, conductor 98, an interlock 99 on the switch 21 and conductor I0! to the negative conductor 49. In this manner, the contact members I08 of the switch 28 are closed to shunt the resistor from the motor circuit, thereby applying maximum voltage to the motors I0 and II.

If it is desired to accelerate the motors by automatic control, instead of by manual control, as just described, the master controller 33 may be initially actuated to position 5 instead of in the step-by-step manner previously described. By actuating the controller 33 to position 5, the motors I0 and II will first be connected to the power source in series with the resistors 23, 24 and 25, and these resistors then shunted from the motor circuit by automatic progression under the control of the limit relays and 36 in the manner herein described, it being necessary for the motor current to be reduced to a predetermined value after the first step in the accelerating progression is taken before the next step can be taken.

If it is desired to accelerate the motors at a higher rate of acceleration, the master controller 33 may be initially actuated to position 6, thereby energizing the entire shunt windings on each of the relays 35 and 36 and deenergizing the contact finger 11, which will increase the force exerted by the shunt windings and cause the limit relays to be raised to their uppermost positions at a higher value of motor current. The circuit through the shunt windings of the limit relay 35 may be traced from a contact finger III, which engages the segments 44 on the controller 33, through conductor II2, the portions H3 and 82 of the shunt winding on the relay 35, and thence through. a circuit previously traced to the negative conductor 49. The circuit through the shunt winding on the relay 36 extends from the previously energized conductor II2 through the windings H4 and 96 on the relay 36, and thence through a circuit previously traced to the negative conductor 49.

It will thus be seen that the motors I0 and II may be accelerated either by manual control in a step-by-step manner, or by automatic progression under the control of the limit relays 35 and 36, which are so connected in the motor circuit that only one step of acceleration can be taken at a time, and that the motor current must be reduced to a predetermined value before the next step in the automatic progression can be taken.

If it is desired to retard the movement of the vehicle by dynamic braking, the accelerating controller 33 must first be returned to the ofi position, and then the braking controller 34 may be advanced step-by-step to produce the desired braking effect. By returning the accelerating controller 33 to the off position, the motors i0 and II are disconnected from the power source, as the line switches I6 and I! are deenergized. Control energy is also supplied to the braking controller 34 through a circuit which extends from contact fingers 42 and I I5, bridged by the segment 44 and conductor II6, to a contact finger II! on the controller 34.

Dynamic braking connections may then be 7 established for the motors I0 and I I by actuating the controller 34 to position I to operate the switches 3|, 32 and H. The circuit through the actuating coil of. the switch 3I may be traced from a contact finger II8, which engages a segment I IE] on the controller 34, through conductor i2i, an interlock I22 on the switch I6, conductor H23, the actuating coil I24 on the switch 3I, and conductor I25 to the negative conductor 49. The circuit for the coil of the switch 32 may be traced from the contact finger I26 on the controller 34 through conductor I21 and the actuating coil I28 of the switch 32 to the negative conductor 49. The circuit for the coil of the switch i1 extends from the previously energized conductor I21 through conductor I29, an interlock 3| on the switch 3i, conductors and 46, the actuating coil 4'?! on the switch I1 and conductor 48 to the negative conductor 49.

The closing of the switches 3!, 32 and I1 establishes dynamic braking connections for the motors I6 and II, the motors being so connected that the current in the armature windings of. the motors is reversed and the field winding of each motor is excited by the armature current of the other motor. The one dynamic braking circuit may be traced from one terminal of the armature 92 of the motor I0, through conductor I32, contact members i33 on the switch 3|, the resistors 25, 24 and 23, conductor 59, contact members 34 on the switch 3I, conductors I35 and I36, the field winding I5 of the motor II, conductors and 64 to the other terminal of the armature I2. The other dynamic braking circuit may be traced from the one terminal of the armature I4 of the motor II through conductor the field winding I3 of, the motor I0, conductor E32, contact members I33, resistors 29, 25, 24 and 23 conductor 59, contact members I34 and conductors I35 and I36 to the other terminal of the armature I4. By connecting the motors in this manner they are caused to function as generators, thereby retarding the movement of the vehicle.

As stated hereinbeiore, provision is made for separately exciting the field winding I5 of the motor Ii from the power source when the dynamic braking connections are first established, thereby insuring that the voltage of the machines i9 and II will build up quickly and dynamic braking take effect immediately. The circuit providing separate excitation for the field winding 55 may be traced from the power conductor 2I, through the current collector I8, conductors 4|, iii and i3'I, resistor 31, contact members I 38 on the switch 32, conductor I36, the field winding I5,

conductor 65, the contact members 66 on the switch I1, conductor 61 and the current collector I8 to the negative power conductor 22. By separately exciting the field winding I5, it is insured that the motor II will immediately start generating current, thereby providing excitation for the field winding l3 of the motor II], which will also function as a generator.

lhe current generated by the machines I and II, and therefore, the braking effect of these machines may be controlled by means of the resistors 23, 24 and 25 and their respective shunting switches, 26, 21 and 28, in a manner similar to that utilized during the acceleration of the motors I0 and II, by closing the switches 26, 2'!

and 28 in sequential relation to shunt the resisters 23, 24 and 25 from the motor circuit.

However, as explained hereinbefore, the closing of the switch 26 which is the first one in the progression, cannot take effect until the voltage of the machines I 0 and II has built up to a predetermined value to operate the relay 38, which controls the energization of the actuating coil of the switch 26, Assuming that the voltage of the machines I0 and II has reached a value which will cause the relay 36 to close its contact members, the switch 26 may be operated to shunt the resistor 23, by actuating the controller 34 to position 2, thereby energizing the actuating coil of the switch 26. The circuit through the coil of this switch may be traced from a contact finger I4I, which engages the segment H9, through conductor I42, the contact members I43 on the relay 38, conductor I2, the actuating coil I3 of the switch 26 and conductor 14 to the negative conductor 49.

The switches 21 and 28 may be closed in sequential relation by either actuating the controller 34 to positions 3 and 4 in a step-by-step manner, under manual control of the operator, or by actuating the controller 34 to position 5, which will cause the switches 21 and 28 to be automatically closed under the control of the limit relays 35 and 36 in the same manner as during the acceleration of the motors I0 and II. In either event, the switch 2"! cannot be closed until the ureter current has been reduced to a value which will permit the limit relay 35 to be operated to close its contact members after the switch 26 has been closed, and the switch 28 cannot be operated until the limit relay 36 has closed its contact members after the switch 2! has been closed.

In this manner, the rate of deceleration of the vehicle by dynamic braking is controlled by the limit relays 35 and 36 in the same manner as the rate of acceleration is controlled. If the maximum rate of deceleration is desired, the controller 34 may be actuated to position 6, thereby energizing the entire shunt windings on the limit relays 35 and 36 and deenergizing the contact finger I8, which will cause the relays to operate at a higher value of motor current, as explained iereinbefore.

Since it is not necessary to provide separate excitation for the field winding I of the motor I I after the voltage of the motors I0 and I I has been built up, the switches 32 and I! are permitted to open when the controller 34 is actuated to position 3, thereby interrupting the exciting circuit after the dynamic braking is established. The resistor 29 is not shunted from the motor circuit during dynamic braking, in order that the dynamic braking eifect will be gradually reduced as the speed of the vehicle is decreased.

From the foregoing description, it is apparent that we have provided a control system which is both simple and fiexible in operation, since it is possible to obtain step-by-step acceleration under the control of a vehicle operator or automatic acceleration at variable rates. By providing a separate limit relay for each step of acceleration, each notch is definitely tested, to make sure that the motor current has dropped to the proper value, before the next step in the progression can be taken, thereby preventing overloading of the motors. Skipping of notches during automatic acceleration is definitely prevented by the action of the limit relays. Furthermore, the progression is obtained in a definite sequence since it is impossible to operate any one of the accelerating switches until the preceding switches have been operated.

We do not desire to be restricted to the specific embodiment of the invention herein shown and 1 described, since it is evident that it may be changed and modified without departing from the spirit and scope of the invention, as defined in the appended claims.

We claim as our invention:

1. In a motor control system, in combination, a plurality of motors, a source of power for operating said motors, switching means for establishing dynamic braking connections for the motors, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting said resistors in sequential relation, relay means responsive to the voltage developed by the motors for controlling the initial operation of said switches, and relay means jointly responsive to the motor current and the potential of said power source for controlling the sequential operation of said switches during dynamic braking.

2. In a motor control system, in combination, a motor, a source of power for operating said motor, switching means for establishing dynamic braking connections for the motor, means for separately exciting the field winding of the motor when dynamic braking connections are established, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting said resistors in sequential relation, means responsive to the voltage developed by the motor for controlling the initial operation of said switches, and means jointly responsive to the motor current and the potential of said power source for controlling the sequential operation of said switches.

3. In a motor control system, in combination, a motor, switching means for establishing dynamic braking connections for the motor, a controller for controlling the operation of said switching means, means for separately exciting the field winding of the motor when dynamic braking connections are established, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting said resistors in sequential relation, means directly responsive to the voltage of the motor for controlling the initial operation of said switches, and means jointly responsive to the motor current and to the position of said controller for controlling the sequential operation of said switches during dynamic braking.

4. In a motor control system, in combination, a motor, switching means for establishing dynamic braking connections for the motor, a controller for controlling the operation of said switching means, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting the resistors in sequential relation, a plurality of current limit relays jointly responsive to the motor current and to the position of the controller for controlling the sequential operation of the resistor shunting switches during dynamic braking, and relay means directly responsive to the voltage of the motor for controlling the initial operation of said switches.

5. In a motor control system, in combination, a motor, switching means for establishing dynamic braking connections for the motor, a controller for controlling the operation of said switching means, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting the resistors in sequential relation and a plurality of current limit relays cooperating with the controller to control the sequential operation of the resistor shunting switches, each of said relays having a series coil energized by the motor current and a shunt coil energized through said controller as the resistor shunting switches are 0perated in sequential relation.

6. In a motor control system, in combination, a motor, switching means for establishing dynamic braking connections for the motor, a controller for controlling the operation of said switching means, a plurality of resistors for controlling the motor current during dynamic braking, a plurality of switches for shunting the re J sistors in sequential relation, a plurality of current limit relays cooperating with the controller to control the sequential operation of the resistor shunting switches, means on said relays associated with said controller for changing the operating characteristics of the relays, and means for preventing the operation of said resistor shunting switches until the motor develops a predetermined voltage.

BASCUM O. AUSTIN. NORMAN H. W'ILLBY. 

